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(11) | EP 0 103 392 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Fortified epoxy resin compositions and process for the preparation thereof |
| (57) Heat curable epoxy resin compositions comprising a resin-forming polyepoxide and
an amine curing agent are fortified (i. e. given increased strength and modulus but
without consequent brittleness) by incorporating into the resin mix prior to curing
up to 40 parts by weight per hundred parts of resin of a fortifying agent which is
the reaction product of an aromatic amine, e. g. aniline, with a mono- or di-epoxide,
the fortifier thus obtained optionally further being reacted with an isocyanate or
nitrile prior to incorporation into the resin mix. |
[0001] This invention relates to tortitied epoxy resin composition and to a process for the preparation thereoi.
[0002] Epoxy resin matrices are usually two-component systems. comprising a resin component [e.g. a diglycidyl ether of bisphenol A (DGEBA)] and a crosslinking agent [e.g. p,p' diaminodiphenylmethane (DDM)]. Diluents or fillers are also otten added tor economic or processing reasons. The resin and curing agent are mixed and "cured", usually at elevated temperatures. The above matrix would typically have a strength of 85 MPa, a modulus of 2800 MPa, a glass transition temperature (Tg, a maximum use temperature) of - 150°C and would fracture in an essentially brittle fashion (H. Lee and K. Neville, "Handbook of Epoxy Resins", McGraw-Hill, New York, 1967). Considerable eftort has been expended to improve on these properties.
[0003] However, no completely satisfactory solution currently exists because improvement in one property has been gained only at the expense of another (e.g. solvent resistance, Tg, ductility, processability, cost).
[0004] Many curing agents or hardeners have been used in epoxy resin systems, in particular amines such as methylene dianiline and tetraethyl- enetriamine. In some cases, adducts of these same amines with mono- or diepoxides have been used as curing agents. In United States Patent No. 4,182,831, January 8, 1980, Hicks, polyepoxide resins are reacted with an aliphatic primary amine mixture, then further reacted with a monoepoxide. United States Patent No. 4,182,832, January 8, 1980, Zondler et al, describes as curing agents for epoxy resins, adducts of substituted 1,4-diaminobutanes and liquid epoxides. United States Patent No. 4,195,152, March 25, 1980, Floyd, describes an adduct of N-alkylpolyamines and monoepoxides as epoxy resin curing agents. United States Patent 4,197,389, April 8, 1980, Becker et al, describes a hardening agent (curing agent) for epoxy resins which is a reaction product of an aliphatic or heterocyclic polyamine, a polyalkylene polyether polyol and at least one polyepoxide. These patents are typical of the more complex curing agents being developed.
[0005] Antiplasticization in highly crosslinked epoxy resin systeme has been reported in the literature. For instance, N. Hata et al, in. J. Appl. Polym. Sci., 17(7), p. 2173-81, 1973, describe pentachlorobiphenyl as the most effective antiplasticizer, and dibutylphthalate an 2,2-bis[4-(2hydroxy-3-phenoxypropoxy)phenyl]propane as less eilectiv. antiplasticizers. There evidently has been little recent interest in this, possibly because materials such as pentachlorubiphenyl are envirou- mentally objectionable.
[0006] The present invention provides an alternative approach to the improvement of the properties of epoxy resins by adding reaction products to the resin which act as fortifiers.
[0007] In one aspect the invention provides a curable epoxy resin composition comprising:
(a) a resin-forming polyepoxide;
(b) an amine curing agent ior (a); and
(c) a fortifier for (a) + (b) comprising the reaction product
of (i) an aromatic amine having an amine group attached to an aromatic ring,
and (ii) a mono- or diepoxide.
[0008] The invention includes this composition cured to a strong, high modulus solid form having a ductile mode of fracture (i.e. slope of stress-strain curve is negative at failure). The reaction product of the aromatic amine and the mono- or diepoxide may be further reacted with an isocyanate or a nitrile to form advantageous fortifiers as described below.
[0009] The invention further includes a process of fortifying an epoxy resin comprising:
(a) reacting (i) an aromatic amine having an amine group attached to an aromatic ring
with (ii) a mono- or diepoxide
to form a fortifier;
(b) mixing the fortifier with a resin-forming polyepoxide and an amine curing agent for said polyepoxide; and
(c) heat curing the mixture to form a strong, high modulus solid having a ductile mode of fracture.
[0010] Preferably in step (a) about 1 mole of amine (i) is heated with about 0.8 to 6 moles (preferably 1-4 moles) of the mono- or diepoxide at the equivalent of about 75-190°C lor about 1hr.
Various physical properties oi epoxy resins fortified in accordance with this invention are illustrated in the accompanying drawings, in which ;
Figure 1 is a graph showing load vs. extension curves for varying concentrations of fortifier in a cured epoxy resin system.
Figure 2 is a graph showing the eftect of fortifier concentration on tensile strength in a cured epoxy resin system for two different fortifiers.
Figure 3 is a graph showing the variation in tensile strength with fortifier concentration for two different resin systems.
[0011] The polyepoxide to be fortified in accordance with this invention can be any resin-forming polyepoxide containing a plurality of reactive 1,2-epoxy groups and curable by reaction with an amine curing agent.
[0012] These polyepoxide materials can be monomeric or polymeric, saturated or unsaturated, aliphatic, cycloaliphatic, aromatic or heterocyclic, and may be substituted, if desired, with other substituents besides the epoxy groups, e.g. hydroxyl groups, ether radicals, aromatic halogen atoms and the like.
[0013] A widely used class of polyepoxides which can be fortified according to the practice of the present invention includes the resinous epoxy polyethers obtained by reacting an epihalohydrin, such as epichlorohydrin, and the like, with either a polyhydric phenol or a polyhydric alcohol. An illustrative, but by no means exhaustive, listing of suitable dihydric phenols includes 4,4'-isopropylidene bisphenol, 2,4'-dihydroxydiphenylethylmethane, 3,3'-dihydroxydiphenyldiethylmethane, 3,4'-dihydroxydiphenylmethylpropylmethane, 2,3'-dihydroxydiphenylethyl- phenylmethane, 4,4'-dihydroxydiphenylpropylphenylmethane, 4,4'-dihydroxy- diphenylbutylphenylmethane, 2,2'-dihydroxydiphenylditolylmethane, 4,4'-dihydroxydiphenyltolylmethylmethane and the like. Other polyhydric phenols which may also be co-reacted with an epihalohydrin to provide these epoxy polyethers are such compounds as resorcinol, hydroquinone, substituted hydroquinones, e.g. p-tert-butylhydroquinone, and the like.
[0014] Among the polyhydric alcohols which can be co-reacted with an epihalohydrin to provide these resinous epoxy polyethers are such compounds as ethylene glycol, propylene glycols, butylene glycols, pentane diols, bis(4-hydroxycyclohexyl)dimethylmethane, 1,4-dimethylolbenzene, glycerol, 1,2,6-hexanetrioL, trimethylolpropane, mannitol, sorbitol, erythritol, pentaerythritol, their dimers, trimers and higher polymers, e.g. polyethylene glycols, polypropylene glycols, triglycerol, dipentaerythritol and the like, polyallyl alcohol, polyhydric thioethers, such as 2,2'-, 3,3'-tetrahydroxydipropylsulfide and the like, mercapto alcohols such as c-monothioglycerol, a,a'-dithioglycerol, and the like, polyhydric alcohol partial esters, such as monostearin, pentaerythritol monoacetate, and the like, and halogenated polyhydric alcohols, such as the monochlorohydrins of glyercol, sorbitol, pentaerythritol and the like.
[0015] Another class of polymeric polyepoxides which can be cured by means of the amine curing agents and fortified, includes the epoxy novolac resins obtained by reacting, preferably, in the presence of a basic catalyst, e.g. sodium or potassium hydroxide, an epihalohydrin, such as epichlorohydrin, with the resinous condensate of an aldehyde, e.g. formaldehyde, and either a monohydric phenol, e.g. phenol itself, or a polyhydric phenol. Further details concerning the nature and preparation of these epoxy novolac resins can be obtained in H. Lee and K. Neville, "Handbook of Epoxy Resins".
[0016] Other suitable polyglycidyl compounds are the polyglycidyl. esters of polycarboxylic acids, such as the polyglycidyl esters of adipic acid, phthalic acid and the like. Polyglycidyl esters of polycarboxylic acids are described in detail in U.S. Patent 2,870,170 to Payne et al. Also suitable are polyglycidyl compounds produced by reacting epichlorohydrin with aromatic amines such as aniline, 2,6-dimethylaniline, p-toluidine, m-chloroaniline, p-aminodiphenyl, m-phenylenediamine, p-phenylenediamine, 4,4'-diaminodiphenyl methane, or with amino phenols such as p-aminophenol, 5-amino-1-n-naphthol, 4-aminoresorcinol, 2-methyl-4-aminophenol, 2-chloro-4-aminophenol and the like. Specific compounds include, among others, N,N-diglycidylaniline, N.N-diglycidyl-2,6-dimethylaniline, N,N,N',N'-tetraglycidyl-4,4'-diaminodiphenyl methane, the triglycidyl derivative of p-aminophenol wherein the aminohydrogen and OH hydrogen atoms are replaced by glycidyl groups.
[0017] It will be appreciated by those skilled in the art that the polyepoxide compositions which can be cured and fortified according to the practice of the present invention are not limited to those containing the above described polyepoxides, but that these polyepoxides are to be considered merely as being representative of the class of polyepoxides as a whole.
[0018] The amine curing agents are any aromatic or aliphatic amine curing agents (hardeners) known in the art. Typical examples are methylene dianiline (MDA), metaphenylenediamine and other aromatic polyamines, diethylamine hydrochloride, diethylenetriamine, triethylenetetramine, diethylaminopropylamine, polyoxypropyleneamines and other aliphatic polyamines. Amine adducts such as reaction products of aliphatic amines with epoxide monomers and amino group-containing polyamides are known amine curing agents and would be operative. Heterocyclic amines such as N-aminoethylpiperazine and ethylmethylimidazole may also be used. We prefer the aromatic polyamines particularly when improved high temperature properties are important.
[0019] Comparative tests with and without amine curing agents have confirmed that the fortifiers are not effective curing agents. For example, a fortifier formed from vinylcyclohexenedioxide and aniline was added to a resin with and without the amine curing agent. Compositions containing 15 and 30 parts by wt. of fortifier per hundred of resin, but no curing agent, did not gel when run through the normal cure cycle. With the curing agent plus fortifier, a significant increase in strength and modulus was achieved.
[0020] The aromatic amine reactant used to form the fortifier has the general formula:
in which A to E are selected from hydrogen, lower alkyl, halogen, halogenated lower alkyl, phenyl, halogenated phenyl, hydroxyl, amino, an alkylene-linked aromatic amine or amide moiety, -GNHX and -gNHX where X is selected from H, lower alkyl and phenyl. The lower alkyl or alkylene groups may have from 1-4 carbon atoms. Suitable compounds include aniline, methylene dianiline, m-phenylenediamine, '4-chloroaniline, 4-bromoaniline, 2,4,6-tribromoaniline, 2,4,6-trichloroaniline, a,a,a-trifluoro-m-toluidene, ortho-toluidine, m- and p-aminophenol, ortho-tolidenelsulfanilamide and anthranilamide.
[0021] The monoepoxide reactant has the general formula
in which A' and B' are selected from hydrogen, halogen, lower alkyl, halogenated lower alkyl, phenyl, halogenated phenyl, and an alkylene-linked aromatic ether moiety. Suitable monoepoxides include ethylene oxide, propylene oxide, epichlorohydrin, styrene oxide and phenylglycidyl ether (PGE).
[0022] The alternative diepoxide reactant contains two vicinal epoxide rings, one of which is less reactive than the other (for structural or chemical reasons). The reactivity of the less reactive epoxide group may be lower because of, e.g., being attached to an alicyclic moiety or by substituents on the alpha-carbons or because of its steric configuration. Suitable dioxides include vinylcyclohexene dioxide, limonene dioxide, bis(2,3-epoxycyclopentyl)ether (liquid isomer), and p-epoxycyclopentyl- phenyl glycidyl ether.
[0023] The fortifier is formed by reacting the aromatic amine and mono- or diepoxide together at a selected temperature, usually within about 70°C to 200°C, for a time within about 15 min. to about 4 hr. Preferably, reaction conditions are selected to be equivalent to 75-190°C for about 1-2 hrs. at a ratio of 1 mole amine to 1 to 4 moles epoxide. The temperature (and time) are selected to give the desired degree and mode of reaction yet not boil off the more volatile components. Depending on exotherms encountered, it may be necessary to cool the reaction vessel to maintain the desired reaction temperature. Typical temperatures and times found operative are illustrated in the examples. Catalysts can be used to facilitate the reaction if desired but we have not found them necessary. Suitable catalysts for the fortifier formation include those of the type of diethylamine hydrochloride, ethylmethylimidazole, alphamethylbenzyldimethylamine, and 2-hydroxybenzyldimethylamine. Suitable catalyst concentrations are about 0.1-0.3X.
[0024] The reaction products are a complex mixture in each case and were used as fortifiers without purification or separation. The reaction products were viscous oils or low melting point solids. Chromatographic analysis of a typical fortifier showed the presence of at least 12 chemical components in measurable amounts. Several fortifiers have been retested after at least one year of storage and they showed no signs of deterioration.
[0025] We have found that (in preparing the fortifiers) when only part of the desired amount of one of the reactants is added initially and reacted, and the remainder introduced later, the reaction product is different than if the full amount had been reacted at one time. Using this variation in properties, it is possible to select both reactants and reaction stages to optimize properties of the fortifier for a particular purpose. It is possible to add a different mono- or diepoxide at a second stage of the reaction to vary the properties further. In the same manner, variations or staged additions of the same or different aromatic amines change the properties of the fortifier somewhat. Thus, it is possible to tailor the fortifier to obtain a desired balance of properties for a particular resin system. For each resin-curing agent system, the fortifier is selected to bestow increased tensile strength and modulus on curing.
[0026] The concentration of fortifier relative to the resin (resin-forming polyepoxide) may range from an effective amount up to about 40 parts per hundred parts of resin (PHR). Amounts within the range of 5-30 PHR normally are preferred.
[0027] These fortifiers will have some free hydroxyl groups available for further reaction. We have found that reaction with isocyanates or nitriles gives fortifiers which bestow increased strengths on the resin (compared to the original fortifier). Any monoisocyanate may be used with typical ones being methyl:, ethyl-, propyl-, and phenylisocyanates and halogenated derivatives thereof. Alternatively, nitrile reactants may be used and these may be mono- or dinitriles. Suitable nitrile reactants include p-aminobenzonitrile, phthalonitrile, malononitrile, succinonitrile, butyronitrile, adiponitrile and acrylonitrile. Halogenated derivatives of these nitriles can be used. Normally, the amount of isocyanate or nitrile will be sufficient to react with all hydroxyl groups present. The reaction conditions with nitrile reactants generally are about 1 hr at about 150 though variations are possible. With the isocyanates, they are added cold and usually in stages since the reaction is exothermic, preferably with the final temperature controlled to be about 120°C.
[0028] The final cure conditions of the resin-forming polyepoxide + amine curing agent + fortifier generally follow conventional epoxy resin cure techniques. Usually at least two cure stages are utilized, with preferred cure sequences being within the ranges:
[0029] Those skilled in the art will be able to determine a suitable cure cycle for any particular system.
Example 1
[0031] Phenylglycidylether was mixed with aniline at a mole ratio of 1.05:1 and 0.25% of diethylamine hydrochloride added as catalyst. The mixture was heated at 100°C for 30 min. and 160°C for 60 min. to give the fortifier designated PGE-A.
[0032] This fortifier was mixed in varying proportions with Epon 828 (trademark for diglycidyether of bisphenol A) as resin-forming polyepox- .ide containing methylene dianiline as curing agent. The actual amount of curing agent was adjusted, depending on the amount of fortifier, to maintain an added active hydrogen to epoxy group ratio of approximately 1:1. The system was cured at 100°C for 3 hrs, + 125°C for 2 hrs, + 175°C for 4 hrs. The tensile strength results are shown in Figure 2. A significant increase in strength was obtained.
Example 2
[0033] Vinylcyclohexene dioxide was mixed with aniline at a mole ratio of 2:1 and 0.25% of diethylamine hydrochloride added as catalyst. The mixture was heated at 190°C for 2 hrs. to give the fortifier designated VCD-A. This fortifier was mixed with Epon 828 containing 30 PHR methylene dianiline curing agent and cured as in Ex. 1. The load vs grip extension curves for 0, 10, 20, 30 and 40 PHR of this fortifier in this system, are shown in Figure 1. The tensile strength results are shown for varying concentrations of fortifier in Fig. 2 and the strength is
[0034] - 9 - seen to increase with concentration of fortifier, i.e. from about 85 MPa to about 120 MPa at 35 PUR fortifier.
Example 3
[0035] Using as resin-forming polyepoxide, the diglycidyl ether of bisphenol A (Epon 828) but with aliphatic amine curing agents, and using the two fortifiers of Ex. 1 and 2, compounding and curing were carried out as follows:
A mixture of 34 parts of a polyoxypropyleneamine (Jeffamine D400 - trademark) and
4 parts of diethylenetriamine was prepared as curing agent, and mixed with 100 parts
of Epon 828 and 30 parts of either the phenylglycidylether-aniline fortifier or the
vinylcyclohexene dioxide -aniline fortifier, then cured at 50°C for 1 hr. + 80°C for
1 hr. + 125°C for 4 hrs. The tensile test results on the cured product were as follows:
Example 4
[0036] In other runs, fortifiers were made using phenylglycidylether, aniline or chloroaniline and in some cases ethyl or phenyl isocyanate. These fortifiers were compounded with Epon 828 resin and 30 PHR MDA and cured at 100°C for 7 hrs. + 160°C for 8 hrs. The results are summarized in Table 1.
[0037] Note that brittle systems were made ductile by increasing the proportion of epoxide in the fortifier.
Example 5
[0038] The effect of fortifying an epoxy novolac resin (DEN 431 - Dow Chemical) compared to Epon 828 was investigated. Varying concentrations of the fortifier VCDA (prepared as in Ex. 2) were added to each resin and the systems cured with 30 PHR methylene dianiline using the cure cycle 100°C for 3 hrs, + 125°C for 2 hrs, + 175°C for 4 hrs. The results are shown in Figure 3. The novolac resin consistently had a strength about 10 MPa higher than the Epon 828 and tensile strengths over 130 MPa (over 19000 psi) were realized.
Example 6
[0039] A nitrile-modified fortifier was prepared by reacting one mole of the VCD-A fortifier of Ex. 2 with one mole of p-aminobenzonitrile by heating to 150°C for 1 hr. Upon compounding various amounts of this fortifier with Epon 828 and 30 PHR MDA and curing as in Ex. 2, the following results were obtained.
[0040] Similar results have been obtained with styrene oxide, propylene oxide and 1,2-epoxybutane as epoxide reactant in forming the fortifier and also with 4-chloroaniline, 2,4,6-trichloroaniline, α,α,α-tri- fluoro-m-toluidine and m-aminophenol as aromatic amine reactant. Still other such reactants would be operative.
Example 7
[0041] A fortifier was made from vinylcyclohexene dioxide and sulfanilamide at a mole ratio of 2.75 : 1 as in Example 2 except heating to 130°C -for 1 hr. This fortifier (VCDSAA) was mixed at 2 proportions with Epon 828 resin containing 30 PHR methylene dianiline curing agent and cured as in Example 1. The results are summarized in Table 2.
Example 8
[0042] A fortifier was made from vinylcyclohexene dioxide and anthranilamide (Q-aminobenzamide) at a mole ratio of 2:1 with heating to 130 C for 1 hr. This fortifier was mixed at 2 proportions with Epon 828 resin and cured as in Example 1. The results arc summarized in Table 3.
Example 9
[0043] A cycloaliphatic epoxy resin (a cyclohexane diepoxy carboxylate) known as Araldite (trademark) CY 179 was fortified and cured. The fortifiers were VCDA and BCDSAA prepared as above and VCDMAP. The later was prepared from vinylcyclohexene dioxide and meta-aminophenol in a mole ratio of 3:1 with heating to 120°C for 1 hr. Curing was for 3 hrs. at 100°C and then 6 hrs. at 180°C. The results are summarized in Table 4.
1. A iortitied curable epoxy resin composition comprising a resin forming polyepoxide
and an amine curing agent therefor, characterized in that the composition further
contains, as a fortifier, the reaction product of i) an aromatic amine having an amino
group attached to an aromatic ring and ii) a mono-diepoxide, said reaction product
optionally being further reacted with an isocyanate or nitrile.
2. A composition according to claim 1, characterized in that the fortifier is the
reaction of a mono- or diepoxide with an amine of the formula
in which A to E are each hydrogen, C1 -C4 alkyl, halogen, halogenated C1-C4 alkyl, phenyl, halogenated phenyl, hydroxyl, amino, an alkylene-linked aromatic amine or amide moiety, or an
group where X is H, C1- C4 alkyl or phenyl.
in which A to E are each hydrogen, C1 -C4 alkyl, halogen, halogenated C1-C4 alkyl, phenyl, halogenated phenyl, hydroxyl, amino, an alkylene-linked aromatic amine or amide moiety, or an
group where X is H, C1- C4 alkyl or phenyl.
3. A composition according to claim 1 or 2,characterized in that the fortifier is
the reaction product of said amine with a monoepoxide of the formula
wherein A' and B' are each hydrogen, halogen, C1-C4 alkyl, halo- genated C1-C4 alkyl, phenyl or halogenated phenyl, or an alkylene-linked aromatic ether moiety.
wherein A' and B' are each hydrogen, halogen, C1-C4 alkyl, halo- genated C1-C4 alkyl, phenyl or halogenated phenyl, or an alkylene-linked aromatic ether moiety.
4. A composition according to claim 1 or 2, characterized in that the fortifier is
the reaction product of said amine with a diepoxide containing two epoxide groups
one oi which is less reactive than the other.
5. A composition according to claim 4, wherein the diepoxide reactant is vinylcyclohexene
dioxide.
6. A composition according to any one of the preceding claims, characterized in that
the fortifier is present in an amount of up to 40 parts by wt. per hundred parts of
resin.
7. A composition according to any one of the preceding claims wherein the amine curing
agent is methylene dianiline, N-aminoethylpiperazine, metaphenylenediamine or ethylmethylimidazole.
8. A composition according to any one of claims 1 to 7, wherein the fortifier is a
reaction product obtained by reacting the amine with said mono- or di-epoxide and
further.reacting the product thus obtained with an isocyanate selected from methyl
isocyanate, ethyl isocyanate, phenyl isocyanate, or a halogenated derivative thereof
or with a nitrile selected from aminobenzonitrile, phthalonitrile, malononitrile,
succinonitrile, adiponitrile, or a halogenated derivative of one of those nitriles.
9. A fortified, cross-linked polyester resin composition according to any one of claims
1 to 8, which has been cured to effect cross-linking of said polyepoxide with said
amine.
10. A method of fortifying amine-cured polyepoxy resin compositions obtained by heat
curing a reaction mixture comprising a resin-forming polyepoxide and an amine curing
agent, characterized by incorporating into the reaction mixture prior to curing a
fortifying agent which comprises the reaction product obtained by reacting i) an aromatic
amine having an amine group attached to an aromatic ring, and ii) a mono- or di-epoxide,
and optionally further reacting said reaction product with a isocyanate or nitrile,
and heat curing the mixture so formed.
11. A method according to claim 10, characterized in that the fortifying agent is
a reaction product obtained by reacting said aromatic amine and said mono- or di-epoxide
at a molar ratio of from 1:0.8 to 1:6 and at a temperature of from 75-190°C for a
period of about 1 houi.
12. A method according to claim 11, characterized in that the fortifying agent is
obtained by reaction of said amine with said mono- or di-epoxide in the presence of
diethylamine hydrochloride, ethylmethylimidazole, alphamethylbenzyldimethylamine or
2-hydroxybenzyldimethylamine.
13. A method according to claim 10, 11 or 12 characterized in that the fortifying
agent is added to the curable resin composition in an amount of from 5-30 parts by
weight, per hundred parts of resin.
14. A method according to any one of claims 10 - 13, characterized in that the fortifier
is as required by any one of claims 1 - 5, 7 and 8 .